Glass mat for roofing products

ABSTRACT

A glass mat includes an assembly of glass fibers, a binder composition and an asphaltic coating. The binder composition includes an organic resin and an adhesion promoter. The glass mat has an at least 2% increase in tear strength as measured using the methods specified in ASTM D3462, compared to an asphaltic coated glass mat having a binder composition without the adhesion promoter. Further provided is an asphalt roofing product including the glass mat and a method of increasing tear strength in an asphalt roofing product.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. application Ser. No.14/150,496, filed Jan. 8, 2014 entitled “GLASS MAT FOR ROOFINGPRODUCTS,” naming inventors Wayne R. Vliet, Missy R. Miller, Ronald LeonFranklin, Jr., Charles G. Herbert, Nancy E. Brown, and Fei Wang whichclaims priority from U.S. Provisional Patent Application No. 61/750,045,filed Jan. 8, 2013, entitled “GLASS MAT FOR ROOFING PRODUCTS,” naminginventors Wayne R. Vliet, Missy R. Miller, Ronald Leon Franklin, Jr.,Charles G. Herbert, Nancy E. Brown, and Fei Wang, which application isincorporated by reference herein in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to a glass mat and in particular, a glassmat for asphalt roofing products.

BACKGROUND

Roofing materials, such as shingles, roll roofing, and commercialroofing, are typically constructed of a glass fiber mat with an asphaltcoating on the fibrous mat, and a surface layer of granules embedded inthe asphalt coating.

Chopped strand mat, suitable for use in roofing material, generallyincludes glass fibers because they are of high strength and tend not toshrink during use. The glass fibers are typically formed by attenuatingstreams of molten glass material from a bushing. The fibers are drawnfrom the bushing and the fibers are then chopped directly into acontainer. The chopped fibers are then dispersed in a water slurry whichcontains surfactants, viscosity modifiers, dispersants and otherchemical agents. The fibers and slurry are agitated to disperse thefibers prior to depositing the mixture onto a moving screen where mostof the water is removed. Although this generally describes a wet-laidprocess, a dry-laid process may be used.

A polymeric binder is then applied. A urea-formaldehyde (“UF”) binder istypically utilized for asphalt roofing product applications due to itslow cost, compatibility with asphalt and resulting high strength. Afterapplication of the polymeric binder, the resulting mat is heated toremove the remaining water and cure the binder. Next, an asphalt coatingthat typically includes a mixture of oxidized asphalt, mineralstabilizer and possibly polymer additives is applied to the mat, such asby spraying the asphalt onto one or both sides of the mat, or by passingthe mat through a bath of molten asphalt in order to place a layer ofasphalt on both sides of the mat. A protective coating of granules maybe applied to the asphalt-coated mat to provide a roofing material, suchas a shingle.

Important properties for a glass mat include dry tensile strength, hotasphalt tensile strength, hot wet tensile strength, and tear strength.These mechanical properties are useful in determining the asphaltroofing product manufacturing and ultimate reinforcing properties in theshingle. Modifications to the glass mats and the binder compositions toimprove such properties are desired.

Accordingly, a need continues to exist in the art for bindercompositions for glass mats that can meet new and sometimes exceeddemanding applications.

SUMMARY

In an embodiment, a glass mat includes an assembly of glass fibers; abinder composition including an organic resin and an adhesion promoterincluding a resin acid additive, a tall oil fatty acid, a rosin, a talloil derivative, or combination thereof; and an asphaltic coating;wherein the glass mat has an at least 2% increase in tear strength asmeasured using the methods specified in ASTM D3462, compared to anasphaltic coated glass mat having a binder composition without theadhesion promoter.

In another embodiment, an asphalt roofing product is provided. Theroofing product includes a glass mat including an assembly of glassfibers; a binder composition including an organic resin and an adhesionpromoter including a resin acid additive, a tall oil fatty acid, arosin, a tall oil derivative, or combination thereof; and an asphalticcoating; wherein the glass mat has an at least 2% increase in tearstrength as measured using the methods specified in ASTM D3462, comparedto an asphaltic coated glass mat having a binder composition without theadhesion promoter.

In yet another embodiment, a method of increasing tear strength in anasphalt roofing product is provided. The method includes providing aglass mat for the asphalt roofing product, wherein the glass matincludes an assembly of glass fibers; a binder composition including anorganic resin and an adhesion promoter including a resin acid additive,a tall oil fatty acid, a rosin, a tall oil derivative, or combinationthereof; and an asphaltic coating; wherein the glass mat has an at least2% increase in tear strength as measured using the methods specified inASTM D3462, compared to an asphaltic coated glass mat having a bindercomposition without the adhesion promoter.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example and are not limited in theaccompanying figures.

FIG. 1 includes a cross-sectional view of a portion of a glass matillustrated in accordance with an embodiment described herein.

Skilled artisans appreciate that elements in the figures are illustratedfor simplicity and clarity and have not necessarily been drawn to scale.For example, the dimensions of some of the elements in the figures maybe exaggerated relative to other elements to help to improveunderstanding of embodiments of the invention.

DETAILED DESCRIPTION

The following description in combination with the figures is provided toassist in understanding the teachings disclosed herein. The followingdiscussion will focus on specific implementations and embodiments of theteachings. This focus is provided to assist in describing the teachingsand should not be interpreted as a limitation on the scope orapplicability of the teachings. However, other teachings can certainlybe used in this application.

Before addressing details of the embodiments described below, some termsare defined or clarified. The term “tear strength” is intended toinclude the cross direction strength of a glass mat including a bindercomposition and an asphalt coating as measured by ASTM D3462. The term“ASTM D3462” is intended to refer to the American Society for Testingand Materials (ASTM) Standard D-3462 Standard Specification for AsphaltShingles Made from Glass Felt and Surfaced with Mineral Granules, whichsets the minimum standard for residential fiberglass roofing shingles.The term “filament” is intended to mean an elongated structure or fiberof any suitable length. The term “mat” is intended to mean a woven ornonwoven fabric that includes any suitable arrangement of filamentsother than an arrangement of filaments in a scrim, including anarrangement of randomly oriented filaments.

As used herein, the terms “comprises”, “comprising”, “includes”,“including”, “has”, “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a method,article, or apparatus that comprises a list of features is notnecessarily limited only to those features but may include otherfeatures not expressly listed or inherent to such method, article, orapparatus. Further, unless expressly stated to the contrary, “or” refersto an inclusive-or and not to an exclusive-or. For example, a conditionA or B is satisfied by any one of the following: A is true (or present)and B is false (or not present), A is false (or not present) and B istrue (or present), and both A and B are true (or present).

Also, the use of “a” or “an” is employed to describe elements andcomponents described herein. This is done merely for convenience and togive a general sense of the scope of the invention. This descriptionshould be read to include one or at least one and the singular alsoincludes the plural, or vice versa, unless it is clear that it is meantotherwise. For example, when a single item is described herein, morethan one item may be used in place of a single item. Similarly, wheremore than one item is described herein, a single item may be substitutedfor that more than one item.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. The materials, methods, andexamples are illustrative only and not intended to be limiting. To theextent not described herein, many details regarding specific materialsand processing acts are conventional and may be found in reference booksand other sources within the structural arts and correspondingmanufacturing arts.

In an embodiment, the present invention provides a glass mat. The glassmat includes an assembly of glass fibers; a binder composition includingan organic resin and an adhesion promoter, such as a resin acidadditive, a tall oil fatty acid, a rosin, a tall oil derivative, orcombination thereof. Further included on the assembly of the glassfibers is an asphaltic coating. The addition of the adhesion promoter tothe binder composition of the glass mat provides an at least 2% increasein tear strength as measured using the methods specified in ASTM D3462,compared to an asphaltic coated glass mat having a binder compositionwithout the adhesion promoter. The glass mat is particularly useful inroofing applications, such as for an asphalt roofing product. The glassmat for asphalt roofing product applications having the bindercomposition and asphaltic coating as described has improved tearstrength, as compared to commercially available roofing shingles havinga binder without the adhesion promoter, and can better provide desirableproperties for asphaltic roofing products. A method of increasing thetear in an asphalt roofing product is further provided.

The binder composition includes any suitable organic resin. The organicresin can include one or more suitable polymers, one or more suitablecopolymers, a suitable blend, or combination thereof. In an embodiment,the organic resin includes materials designed to withstand hot asphaltcoating during the asphalt roofing product making process. In aparticular embodiment, the organic resin is a thermosetting resin. Forinstance, the thermosetting resin is a urea-formaldehyde resin. Thethermosetting urea-formaldehyde (UF) resin used as the major componentof the binder composition of the present invention can be prepared fromurea and formaldehyde monomers or from UF precondensates in any suitablemanner Any suitable form of the urea and the formaldehyde reactants isenvisioned. In an embodiment, any form of the urea and the formaldehydereactants which can react and which do not introduce extraneous moietiesdeleterious to the desired reaction and reaction product can be used inthe preparation of urea-formaldehyde resins useful in the invention.

Formaldehyde for making a suitable UF resin is available in many forms.Paraform (solid, polymerized formaldehyde) and a formalin solution (anaqueous solution of formaldehyde, sometimes with methanol, for example,with any suitable concentration of formaldehyde, such as greater thanabout 35% by weight, such as about 37% by weight, about 44% by weight,or about 50% by weight formaldehyde concentrations) are commonly usedforms. Formaldehyde also is available as a gas. Any of these forms issuitable for use in preparing a urea-formaldehyde resin in the practiceof the invention. In a particular embodiment, the formalin solution isthe formaldehyde source.

Similarly, urea is available in many forms. Solid urea, such as prill,and urea solutions, typically aqueous solutions, are commonly available.Further, urea may be combined with another moiety, most typicallyformaldehyde and urea-formaldehyde adducts, often in aqueous solution.Any form of urea or urea in combination with formaldehyde is suitablefor use in the practice of the invention. In a particular embodiment,both urea prill and combined urea-formaldehyde products are used, suchas Urea-Formaldehyde Concentrate or UFC 85.

Any of the wide variety of procedures used for reacting the principalurea and formaldehyde components to form the urea-formaldehydethermosetting resin composition also can be used, such as staged monomeraddition, staged catalyst addition, pH control, amine modification andthe like. Generally, the urea and formaldehyde are reacted at a moleratio of formaldehyde to urea in the range of about 1.1:1 to about 4:1,such as at a formaldehyde to urea mole ratio of about 2.1:1 to about3.2:1. Generally, the urea-formaldehyde resin is highly water dilutable,if not water soluble.

The reactants for making the urea-formaldehyde resin may also include anamount of resin modifiers such as ammonia, alkanolamines, or polyamines,such as an alkyl primary diamine, e.g., ethylenediamine (EDA).Additional modifiers, such as melamine, ethylene ureas, and primary,secondary and tertiary amines, for example, dicyanodiamide, can also beincorporated into urea-formaldehyde resins used in the invention.Concentrations of these modifiers in the reaction mixture often willvary from 0.05% to 20.0% by weight of the urea-formaldehyde resinsolids. These types of modifiers may be used to promote hydrolysisresistance, polymer flexibility and lower formaldehyde emissions in thecured resin. Further urea additions for purposes of scavengingformaldehyde or as a diluent also may be used.

In an exemplary embodiment, the urea-formaldehyde composition is furthermodified with a cross-linking component. Any suitable cross-linkingcomponent is envisioned. Exemplary cross-linking components include, butare not limited to, a styrene maleic anhydride copolymer, a styreneacrylic, an organosilane such as aminoethylaminopropyltrimethoxysilane,aminopropyltriethoxysilane, vinyl benzyl silane, and the like, an epoxy,a polyaziridine, an isocyanate, a zinc salt, a zirconium salt, anN-methylol acrylamide, an isobutoxymethylacrylamide, anacrylamidoglycolic acid monohydrate, anN-(2,2′-hydroxy-1-dimethoxyethyl)acrylamide, a blocked isocyanate, anacetoacetoxyethyl methacrylate (AAEM), a TACT triazine, a titanate salt,sodium borate (Borax), the like, or a combination thereof.

In an embodiment, the urea-formaldehyde composition is modified with astyrene-maleic anhydride (SMA) copolymer. Such styrene-maleic anhydride(SMA) copolymers include alternating styrene and maleic anhydridemonomer units, arranged in random, alternating or block form. Modifiedstyrene-maleic anhydride copolymers, such as copolymers that arepartially esterified or copolymers containing sulfonate groups on thebenzene ring, also can be used according to the present invention.Suitable styrene-maleic anhydride copolymers for practicing the presentinvention may typically have a weight average molecular weight fromabout 1,000 to about 500,000. Such styrene-maleic anhydride (SMA)copolymers are unneutralized, and are initially insoluble in water.However, after a sufficient extent of neutralization using any suitablealkaline substance, such as a hydroxide, like sodium hydroxide,potassium hydroxide, ammonium hydroxide, lithium hydroxide, or cesiumhydroxide; a carbonate, like sodium carbonate, potassium carbonate orammonium carbonate; ammonia or an amine, the styrene-maleic anhydridecopolymers become neutralized to provide solubility in water. In anembodiment, a strongly basic alkali metal compound can be used forneutralizing the SMA copolymer, such as ammonium hydroxide, potassiumhydroxide, sodium hydroxide, lithium hydroxide, cesium hydroxide,ammonium carbonate, potassium carbonate, sodium carbonate, or acombination thereof. Although it generally is desirable to use theneutralizing agent in an amount sufficient to neutralize 100 mole % ofthe SMA copolymer, in an embodiment it is suitable to neutralize the SMAcopolymer at less than 100 mole %, such as at a neutralizationsufficient to obtain water solubility of the SMA copolymer. The level ofaddition of any particular neutralizing agent to obtain an acceptabledegree of water solubility is well within the normal skill in the art.Typically, the styrene-maleic anhydride copolymer is provided to thebinder composition of this invention as a water-soluble styrene-maleicanhydride copolymer.

Suitable styrene-maleic anhydride copolymers for use in accordance withthe method of the present invention are commercially available from, forexample, ARCO Chemical Co., Elf Atochem, Georgia Pacific Resins, Inc.and others. Suitable binders can be prepared by mixing theurea-formaldehyde and the styrene-maleic anhydride copolymer, on asolids basis, in a UF:SMA weight ratio between about 99.9:0.1 to about70:30, such as between about 99.8:0.2 to about 90:10, or even betweenabout 99.8:0.2 to about 95:5. In an embodiment, any suitable amount of across-linking component may be envisioned.

Many urea-formaldehyde resins which may be used in the practice of theinvention are commercially available. In an embodiment, theurea-formaldehyde resin typically has a desirable viscosity forapplication as a binder composition on the glass mat. For instance, theviscosity of the urea-formaldehyde resin is about 50 centipoise (cps) toabout 500 cps, such as about 150 cps to about 300 cps. Further, theurea-formaldehyde has a desirable pH for application to the assembly offibers, such as a pH of about 7.0 to about 9.0, or even a pH of about7.5 to about 8.5. Urea-formaldehyde, such as the type sold by GeorgiaPacific Corporation for glass mat application, and those sold byMomentive Chemical Company may be used.

In a particular embodiment, the binder composition includes an adhesionpromoter such as a resin acid additive, a fatty acid additive, a rosin,a tall oil derivative, or combination thereof, which are typicallycomponents of or are derived from components of a tall oil. Typically,the adhesion promoter includes the resin acid additive, the tall oilfatty acid, the rosin, the tall oil derivative, or combination thereofpresent to provide enhanced compatibility of the binder composition tothe components of the mat, such as the assembly of fibers and theasphaltic coating. Any suitable tall oil based additive is envisioned.Any suitable resin acid additive is envisioned. For example, resin acidsare diterpene monocarboxylic acids, generally isomers of general formulaC₂₀H₃₀O₂. Their name “resin” comes from the fact that they aresynthesized by plants, in particular resinous plants. Any tall oil fattyacid additive is envisioned. Typically, tall oil fatty acid is anothercomponent of tall oils that are mixtures of long chain oligomersconsisting mainly of oleic and linoleic acids and other similarcompounds. Many of these compounds contain double bond functionalitythat can dimerize or trimerize during the separation process from thecrude tall oil mixture. Any tall oil derivative is envisioned that isderived from the tall oil purification process. Useful tall oilderivatives such as rosin soaps, purified dimer and trimer fatty acidsas well as esterified rosin ester gums, and maleic anhydride modifiedrosins also provide enhanced compatibility to asphalt.

Resin acids are divided into several categories depending on their basicchemical structure. Thus, structures of the following types aredistinguished: abietane, pimarane/isopimarane which have three ringscontaining six carbons connected along one side, or else labdane. Theresin acids have a carboxylic acid functionality and at least one doublebond, generally two or three double bonds, including two conjugatingdouble bonds for acids of abietane structure. The most common resinacids are for the group of abietanes: abietic acid (CAS No. 514-10-3),neoabietic acid (CAS No. 471-77-2), palustric acid (CAS No. 1945-53-5),levopimaric acid (CAS No. 79-54-9) and dehydroabietic acid (CAS No.1740-19-8); and for the group of pimaranes: pimaric acid (CAS No.127-27-5), isopimaric acid (CAS No. 5835-26-7) and sandaracopimaric acid(CAS No. 471-74-9). Tall oil fatty acids are generally composed ofpalmitic and shorter carbon chain fatty acids, oleic acid, linoleic,conjugated linoleic and linolenic acid, stearic acid, and eicosatrienoiceicosadienoic acids.

In an embodiment, the resin acid and the fatty acid may be obtaineddirectly from pine oleoresin. Typically, resin acids are the mainnon-volatile component of pine resin. Typically, fatty acids are themain volatile component of pine resin. After evaporation by distillationof certain volatile elements (such as terpenes, for example, α-pinene),the solidified resin or rosin is composed of about 90% by weight ofresin acids, predominantly abietic acid (such as about 40% to about50%), based on the total % weight of the resin acid.

Resin acids and fatty acids may be obtained as by-products of the“Kraft” process of paper manufacture. They are then part, with fattyacids, of what is commonly known as tall oil or pine oil. Variousdistillations make it possible to obtain a tall oil that is more or lesspurified and therefore more or less rich in resin acids. The rosin usedmay be produced either from tall oil (“pine oil rosin”), or directlyfrom pine resin (“pine turpentine rosin”), or else from aged pine stumps(“wood rosin”). In an embodiment, the rosin is obtained from tall oiland then typically includes a larger proportion of pimarane-type acidscompared to the abietic and other rosin acid components. In a particularembodiment, the tall oil based additive is distilled tall oil thatincludes fatty acids, such as, for example, those mainly of the oleictype.

Other exemplary adhesion promoters for the glass mat include, but arenot limited to, lethicin, an asphalt compatible wax such as ClariantLicomont BS 100, a chlorinated olefin wax (such as Airflex CEN203Emulsion), a polyethylene acrylic acid emulsion (such as Michem Prime4983-40F), a starch grafted styrene acrylic (Degree 40+, Solv.), anemulsified asphalt, a organosilane such as vinyl benzyl silane, a fattyacid alcohol, a fatty acid polyethylene oxide (PEO), a maleic anhydridemodified butyl rubber, Shellac, a rosin, a rosin soap, a rosin gum, amaleic anhydride modified rosin, an animal glue, a vegetable oil, a talloil dimer plus trimer acid, an epoxidized soybean oil, a CAPA triol, awheat protein, a vegetable wax (Carnauba, sunflower, rice bran, and thelike), a maleic anhydride modified polypropylene and polyethylene, apolyethylene acrylic acid, a polyethylene glycol-polyethylene copolymer,a polypropylene glycol-polyethylene copolymer, the like, or acombination thereof. In a particular embodiment, the adhesion promoteris in the form of a waterborne emulsion or dispersion.

In an embodiment, the adhesion promoter may be present at any suitableamount to enhance the adhesion of the binder composition to the glassmat to increase the bonding strength between the assembly of fibers. Ina further embodiment, the adhesion promoter is present at an amount toincrease the adhesion of the asphaltic coating to the glass mat andbinder composition. For instance, the adhesion promoter is present at anamount of up to about 10.0% by weight, such as not greater than about5.0% by weight, such as not greater than about 4.0% by weight, or evennot greater than about 3.0% by weight, based on the total % by weight ofthe binder composition. In an embodiment, the adhesion promoter ispresent at an amount of about 1.0% by weight to about 5.0% by weight,based on the total weight % of the binder composition. In an exemplaryembodiment, the resin acid additive, the tall oil fatty acid, the rosin,the tall oil derivative, or combination thereof is present at an amountof up to about 10.0% by weight, such as not greater than about 5.0% byweight, such as not greater than about 4.0% by weight, or even notgreater than about 3.0% by weight, based on the total % by weight of thebinder composition. In a particular embodiment, the resin acid additive,the tall oil fatty acid, the rosin, the tall oil derivative, orcombination thereof is present at an amount of about 1.0% by weight toabout 5.0% by weight, based on the total weight % of the bindercomposition.

The binder composition can also include any suitable additive. Forinstance, the binder composition may include an additional polymercomponent to increase tensile strength, such as an acrylic latex andmore particularly, a cross-linking acrylic latex. In an embodiment, theacrylic latex is present at an amount of up to about 15.0% by weight,based on the total weight % of the binder composition. The bindercomposition may also contain a variety of other known additives such asa silica colloid to enhance fire resistance, antifoamers, biocides,pigments, the like, or combinations thereof. In an embodiment, thebinder composition can include less than about 25% by weight ofadditives, based on the total weight of the binder composition. Inanother embodiment, the binder composition is substantially free ofadditives. “Substantially free” as used herein refers to less than about1% by weight of additives, less than about 0.5% by weight of additives,or even less than about 0.1% by weight of additives, based on the totalweight of the binder composition.

To prepare the binder composition, the organic resin and the adhesionpromoter may be added to the assembly of fibers by any suitable means.The binder composition is used to fixedly bond the assembly of fibers.They may be added separately or in combination. In a particularembodiment, the organic resin and the adhesion promoter are mixedtogether in a desired proportion under ambient conditions. In anembodiment, the adhesion promoter that is not originally dispersed inwater should be emulsified (or dispersed in the case of the waxes)before the adhesion promoter is added to the binder composition. Asdescribed the organic resin and adhesion promoter are added together inthe binder composition. In an embodiment, any other sequence of addingthe components of the binder composition is envisioned. For instance,the organic resin of the binder composition may be applied to theassembly of fibers and the adhesion promoter added in a subsequent step.For instance, the adhesion promoter they can be sprayed or gravity feedon top of the web before the organic resin of the binder composition iscured. In an alternative embodiment, the adhesion promoter can beapplied after the organic resin of the binder composition is cured.

The total concentration of components in the binder composition in anaqueous solution can vary widely in accordance with the practice of thepresent invention, but it will usually be found convenient andsatisfactory to make up this composition at total solids concentrationin the range from about 5% by weight to about 40% by weight, such asabout 20% by weight to about 30% by weight of the total aqueous bindercomposition. As used herein, the solids content of a composition ismeasured by the weight loss upon heating a small, for example, about 1gram to about 5 grams, sample of the composition at 105° C. for 3 hours.

The glass mat includes the binder composition on the assembly of fibers.The assembly of fibers can include a variety of suitable materials. Forinstance, the assembly of fibers can include a glass fiber, such as afiber made from A-type glass fiber, a C-type glass fiber, an E-typeglass fiber, an S-type glass fiber, an E-CR-type glass fiber, a woolglass fiber, or a combination thereof. Any suitable configuration of theassembly of fibers is envisioned. In an embodiment, the assembly offibers may be in a non-woven mat. In a particular embodiment, theassembly of fibers can be any length such as continuous strand, chopped,or combination thereof. In a more particular embodiment, the assembly offibers is chopped into suitable random lengths to provide randomlydisposed fibers.

An exemplary method of forming a glass fiber mat in accordance with thepresent invention begins with an assembly of fibers, such as choppedbundles of glass fibers of suitable length. While reference is madeusing chopped bundles of glass fibers, other forms of glass fibers, suchas continuous strands, may also be used. Generally, fibers having alength of about 0.75 inches to about 3 inches and a diameter of about 3microns to about 20 microns are used. Each assembly may contain about20-300 or more, of such fibers. The assembly of fibers is added to adispersant medium to form an aqueous slurry, know in the art as “whitewater”. The white water typically contains about 0.5% glass,dispersant(s), viscosity modifier(s), foam control and biocideadditives. The fibrous slurry is then agitated to form a workable,uniform dispersion of glass fiber having a suitable consistency. Thedispersant may contain polyacrylamide, hydroxyethyl cellulose, and otheradditive such as surfactants, lubricants, defoamers, the like, orcombinations thereof.

The fiber and white water dispersion is then passed onto a mat-formingmachine containing a mat forming screen. The dispersion is usuallydiluted with water to a lower fiber concentration prior to beingdispersed on a screen. The fibers are collected at the screen in theform of a wet fiber mat, and the excess water is removed by gravity or,more preferably, by vacuum in a conventional manner, such as by vacuumboxes. Although this generally describes a wet-laid process, a dry-laidprocess may also be envisioned. For instance, with a dry-laid process,fibers may be spun from a bushing directly onto a moving web. The bindercomposition is subsequently applied.

The binder composition is traditionally applied to the gravity- orvacuum-assisted de-watered white glass mat. Application of the bindercomposition may be accomplished by any conventional means, such as bysoaking the mat in an excess of binder solution, or by coating the matsurface by means of a binder applicator such as a sprayer or roll. Thecomponents of the binder composition may be applied separately or mixedtogether by any method envisioned. For instance, if applied separately,the components of the binder composition may be added by the same or adifferent method. The amount of binder applied to the mat also can varyconsiderably in the broad practice of the present invention, butloadings in the range of about 3% to about 45% by weight, such as about10% to about 40% by weight, such as about 15% to about 25% by weight, oreven about 20% to about 28% by weight of binder composition based on thedry weight of the bonded mat, will be found advantageous. For glassfibrous mats, this value can normally be confirmed by measuring thepercent loss on ignition (LOI) of the glass mat product.

Following application of the binder composition, the glass fiber mat isde-watered by any reasonable means, such as under vacuum, to removeexcess binder solution. The mat is then dried and the binder compositionis cured in an oven at elevated temperatures, generally at a temperatureof at least about 200° C., for a time sufficient to cure the organicresin. Heat treatment alone is usually sufficient to effect curing.Catalytic curing may also be used, such as a latent acid catalyst. In anembodiment, the cured glass mat generally includes about 80% by weightto about 88% by weight glass fibers, and about 12% by weight to about20% by weight of binder, based on the total weight of the assembly offibers and binder composition.

Further disposed on the glass mat is at least one asphaltic coating.Typically, the finished glass mat with asphaltic coating is used toprepare an asphalt roofing product, such as a roofing shingle. In theasphalt roofing product, the main role of the asphalt is to render thematerial impermeable to water. It also acts as support for the granulesand strengthens the material, and its highly ductile nature makes itpossible to obtain a flexible product which is easy to use. As a generalrule, the lifetime of the asphalt roofing product increases with theamount of asphalt. The asphaltic coating typically includes byproductsderived from the oil industry, such as simple or air-blown pitches orasphalts.

The asphaltic coating can include modifying agents, for examplepetroleum oils, fractions or residues, polymeric materials, such asblock copolymers, for example of styrene-butadiene-styrene type, mineralstabilizing agents or antistatic agents. In an embodiment, the totalcontent of these modifying agents generally does not exceed 15% of thetotal weight of the asphalt composition. In an embodiment, the asphaltcoating can also include up to 25% by weight, based on the total weightof the asphalt composition, of one or more amorphous polyolefins, forexample, chosen from atactic polypropylenes or from copolymers ofethylene and propylene. In a particular embodiment, the amorphouspolyolefins exhibit a softening temperature of between 130° C. and 160°C. The asphalt coating can also include a mineral stabilizer. Anysuitable stabilizer is envisioned and includes, for example, calciumcarbonate, talc, carbon black, fly ash, or a combination thereof. In anembodiment, the stabilizer is present in any suitable amount such asabout 60 weight % to about 70% by weight of the asphalt composition.

The asphaltic coating may be provided by any suitable means. Methods ofapplying the asphalt coating includes molten laid coating, spraying,dipping, the like, or combination thereof. For instance, the glass matwith the binder composition may be coated with molten asphalt on atleast one major surface. In a particular embodiment, an asphalticcoating may be on both a first major surface and a second major surfaceof the assembly of fibers. Typically, the asphaltic coatingsubstantially contacts the major surface to which it is disposed on. Inan embodiment, the asphaltic coating substantially impregnates aplurality of interstices between the assembly of fibers in the mat.“Substantially impregnates” as used herein refers to a depth within theglass mat of at least about 75% to about 100% of the total depth of theglass mat. In a further embodiment, the glass mat can include anysuitable number of asphaltic coatings as described herein. For example,the glass mat can include more than one asphaltic coating, each of whichis substantially impregnated to a suitable depth from opposite majorsurfaces of the assembly of fibers. Typically, the asphaltic coating ispresent on the glass mat as a continuous, uniform coating. In anembodiment, any asphaltic coating is envisioned and the components andamounts can vary due to product and process requirements. In a moreparticular embodiment, the asphaltic coating provides a mass per area ofasphalt of at least about 732 g/m² as measured using the methodsspecified in ASTM D3462.

To form an asphalt roofing product for commercial application, furthermaterials may be added to glass mat. In an embodiment, granules aredistributed over a first asphaltic coating of the first major surface ofthe assembly of fibers and a release agent such as, for example, talc isapplied to a second asphaltic coating of the second major surface of theassembly of fibers. The combined product may be passed between therollers of a cooled calender, so as to partially embed the granules inthe hot asphalt, and the product, once cooled, is collected in the formof a winding or of sheets cut to the desired size.

Turning to FIG. 1, a cross-sectional view of a portion of a glass mat100 is illustrated in accordance with an embodiment described herein.The glass mat 100 includes an assembly of filaments 110 where theassembly of filaments 110 is fixedly bonded by a binder composition (notshown). Further included is at least one layer of an asphaltic coating120. The at least one layer of the asphaltic coating 120 may be disposedon a first major surface 130 of the assembly of filaments 110. Anynumber of layers of the asphaltic coating 120 can be provided in theglass mat 100 and can be positioned directly on the assembly offilaments 110. As illustrated, the asphaltic coating 120 can be disposedon at least two surfaces of the assembly of filaments 110. Although notillustrated, any number of further layers may be included within theglass mat to further enhance any desirable properties of the finalasphalt roofing product. For instance, a scrim may be included, such asdisposed on the assembly of filaments 110, such as directly contactingthe assembly of filaments 110. A “scrim” may also be known as a“laid-scrim” and typically describes a fabric that is non-woven withwarp yarns and weft yarns.

The glass mat and asphalt roofing product as described can includesuitable properties, such as tear strength, weight, and suitable loss onignition (LOI) values. For instance, an exemplary asphalt roofingshingle of the present invention has a tear strength of at least about1700 grams, at least about 1900 grams, such as at least about 2100grams, or even greater as measured using the methods specified in ASTMD3462. The addition of the adhesion promoter to the glass mat providesan at least 2% increase, such as at least 5% increase, such as at least10% increase, or even greater than a 20% increase in tear strength asmeasured using the methods specified in ASTM D3462, compared to anasphaltic coated glass mat having a binder composition without theadhesion promoter. Moreover, it will also be appreciated that a glassmat having the binder composition of the present invention can obtainconventional and minimum tear strength values as required by ASTM D3462without a conventional amount of the assembly of fibers. That is, aglass mat with the binder composition of the present invention canincorporate less assemblage of fibers than a conventional glass mat andstill obtain the minimum tear strength values as required by ASTM D3462.

In an embodiment, the glass mat of the present invention can have aweight of about 0.5 pound/100 square feet to about 6.0 pound/100 squarefeet. In a particular embodiment, the glass mat product with the bindercomposition as described can be effective at a lower weight, such as aweight of about 0.5 pound/100 square feet to about 4.0 pound/100 squarefeet, compared to a conventional glass mat product. The lower weightglass mat product can advantageously allow asphalt roofing productmanufacturers to use less raw materials and achieve the same or improvedperformance compared to a conventional glass mat product.

In an embodiment, the glass mat can include a loss of ignition (LOI)value of not greater than about 30%, such as not greater than about 25%,or even not greater than about 20%, depending on the weight percentageof the binder composition included relative to the total weight of theglass mat.

The glass mat and the asphalt roofing product made therefrom of thepresent invention represents a departure from and improvement overconventional glass mat and asphalt roofing product. Without wishing tobe tied to a particular theory, the glass mat with the bindercomposition of the present invention provides improved adhesion of theassembly of fibers as well as the asphalt coating to the assembly offibers, resulting in a higher tear strength, in particular, for anasphaltic coated glass mat.

Many different aspects and embodiments are possible. Some of thoseaspects and embodiments are described herein. After reading thisspecification, skilled artisans will appreciate that those aspects andembodiments are only illustrative and do not limit the scope of thepresent invention. Embodiments may be in accordance with any one or moreof the items as listed below.

Item 1. A glass mat including an assembly of glass fibers; a bindercomposition including an organic resin and an adhesion promoterincluding a resin acid additive, a tall oil fatty acid, a rosin, a talloil derivative, or combination thereof; and an asphaltic coating;wherein the glass mat has an at least 2% increase in tear strength asmeasured using the methods specified in ASTM D3462, compared to anasphaltic coated glass mat having a binder composition without theadhesion promoter.

Item 2. An asphalt roofing product, wherein the asphalt roofing productincludes a glass mat including an assembly of glass fibers; a bindercomposition including an organic resin and an adhesion promoterincluding a resin acid additive, a tall oil fatty acid, a rosin, a talloil derivative, or combination thereof; and an asphaltic coating;wherein the glass mat has an at least 2% increase in tear strength asmeasured using the methods specified in ASTM D3462, compared to anasphaltic coated glass mat having a binder composition without theadhesion promoter.

Item 3. A method of increasing tear strength in an asphalt roofingproduct, the method including providing a glass mat for the asphaltroofing product, wherein the glass mat includes: an assembly of glassfibers; a binder composition including an organic resin and an adhesionpromoter including a resin acid additive, a tall oil fatty acid, arosin, a tall oil derivative, or combination thereof; and an asphalticcoating; wherein the glass mat has an at least 2% increase in tearstrength as measured using the methods specified in ASTM D3462, comparedto an asphaltic coated glass mat having a binder composition without theadhesion promoter.

Item 4. The glass mat, the asphalt roofing product, or the method of anyone of Items 1-3, wherein the organic resin includes a urea-formaldehydecomposition.

Item 5. The glass mat, the asphalt roofing product, or the method ofItem 4, wherein the urea-formaldehyde composition includes astyrene-maleic-anhydride modified urea formaldehyde.

Item 6. The glass mat, the asphalt roofing product, or the method of anyone of Items 1-5, wherein the adhesion promoter includes a tall oilfatty acid.

Item 7. The glass mat, the asphalt roofing product, or the method of anyone of Items 1-6, wherein the adhesion promoter is present at an amountof up to about 10.0% by weight, based on the total weight % of thebinder composition.

Item 8. The glass mat, the asphalt roofing product, or the method ofItem 7, wherein the adhesion promoter is present at an amount of about1.0% by weight to about 5.0% by weight, based on the total weight % ofthe binder composition.

Item 9. The glass mat, the asphalt roofing product, or the method of anyone of Items 1-8, wherein the binder composition further includes anacrylic latex present at an amount of up to about 15.0% by weight, basedon the total weight % of the binder composition.

Item 10. The glass mat, the asphalt roofing product, or the method ofany one of Items 1-9, wherein the binder composition fixedly bonds theassembly of fibers.

Item 11. The glass mat, the asphalt roofing product, or the method ofany one of Items 1-10, wherein the binder composition is about 15% byweight to about 25% by weight of the glass mat.

Item 12. The glass mat, the asphalt roofing product, or the method ofany one of Items 1-11, wherein the assembly of fibers includes anon-woven mat.

Item 13. The glass mat, the asphalt roofing product, or the method ofItem 12, wherein the non-woven mat includes randomly disposed fibers.

Item 14. The glass mat, the asphalt roofing product, or the method ofany one of Items 1-13, wherein the assembly of fibers includes an A-typeglass fiber, a C-type glass fiber, an E-type glass fiber, an S-typeglass fiber, an E-CR-type glass fiber, a wool glass fiber, or acombination thereof.

Item 15. The glass mat, the asphalt roofing product, or the method ofany one of Items 1-14, wherein the glass mat has a weight of about 0.5pound/100 square feet to about 6.0 pound/100 square feet.

Item 16. The glass mat, the asphalt roofing product, or the method ofany one of Items 1-15, wherein the glass mat has a weight of about 0.5pound/100 square feet to about 4.0 pound/100 square feet.

Item 17. The glass mat, the asphalt roofing product, or the method ofany one of Items 1-16, wherein the asphaltic coating includes astabilizer.

Item 18. The glass mat, the asphalt roofing product, or the method ofItem 17, wherein the stabilizer includes calcium carbonate, talc, carbonblack, fly ash, or a combination thereof.

Item 19. The glass mat, the asphalt roofing product, or the method ofany one of Items 1-18, wherein the asphaltic coating is positioneddirectly on a first major surface of the assembly of fibers.

Item 20. The glass mat, the asphalt roofing product, or the method ofItem 19, wherein the asphaltic coating substantially impregnates aplurality of interstices between the assembly of fibers.

Item 21. The glass mat, the asphalt roofing product, or the method ofany one of Items 1-20, wherein the asphaltic coating is positioneddirectly on a second major surface of the assembly of fibers.

Item 22. The glass mat, the asphalt roofing product, or the method ofany one of Items 1-21, wherein the asphaltic coating is a dippedcoating, a sprayed-on coating, a molten laid coating, or a combinationthereof.

Item 23. The glass mat, the asphalt roofing product, or the method ofany one of Items 1-22, wherein the glass mat further comprises a loss onignition (LOI) value of not greater than about 30%.

The following examples are provided to better disclose and teachprocesses and compositions of the present invention. They are forillustrative purposes only, and it must be acknowledged that minorvariations and changes can be made without materially affecting thespirit and scope of the invention as recited in the claims that follow.

EXAMPLES Example 1

Two exemplary asphaltic coated glass mats are formed. Control sample isan asphaltic coated chopped fiber randomly distributed glass mat havinga urea-formaldehyde binder composition. Sample 1 is similar to theControl Sample having a urea-formaldehyde binder composition with theaddition of 3% tall oil fatty acid. Tear strength is measured inaccordance with ASTM-D3462. The Control sample has a tear strength of1366 grams and Sample 1 has a tear strength of 1991 grams, demonstratingthe benefit of the adhesion promoter to the urea-formaldehyde bindercomposition. The increase in tear strength is 46%.

Example 2

Two exemplary asphaltic coated glass mats are formed. Control sample isan asphaltic coated chopped fiber randomly distributed glass mat havinga standard urea-formaldehyde binder composition. Sample 2 is similar tothe Control sample having a urea-formaldehyde binder composition withthe addition of 3% tall oil fatty acid and a 5% self-crosslinkingacrylic latex. Tear strength is measured in accordance with ASTM-D3462.The Control sample has a tear strength of 1675 grams and Sample 2 has atear strength of 1869 grams, demonstrating the benefit of increased tearstrength with the addition of the adhesion promoter to theurea-formaldehyde binder composition.

Example 3

Two exemplary asphaltic coated glass mats are formed. Control sample isan asphaltic coated chopped fiber randomly distributed glass mat havinga standard urea-formaldehyde binder composition. Sample 3 is similar tothe Control Sample having a urea-formaldehyde binder composition withthe addition of 3% tall oil fatty acid and 6% self-crosslinking acryliclatex. Tear strength is measured in accordance with ASTM-D3462. Controlsample has a tear strength of 1727 grams and Sample 3 has a tearstrength of 1855 grams, demonstrating the benefit of increased tearstrength with the addition of the adhesion promoter to theurea-formaldehyde binder composition.

Clearly, the data from the Examples demonstrates that the addition ofthe adhesion promoter, such as the tall oil fatty acid increases thetear strength compared to the Control samples without any tall oil fattyacid.

Certain features, for clarity, described herein in the context ofseparate embodiments, may also be provided in combination in a singleembodiment. Conversely, various features that are, for brevity,described in the context of a single embodiment, may also be providedseparately or in any subcombination. Further, reference to values statedin ranges includes each and every value within that range.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims.

The specification and illustrations of the embodiments described hereinare intended to provide a general understanding of the structure of thevarious embodiments. The specification and illustrations are notintended to serve as an exhaustive and comprehensive description of allof the elements and features of apparatus and systems that use thestructures or methods described herein. Separate embodiments may also beprovided in combination in a single embodiment, and conversely, variousfeatures that are, for brevity, described in the context of a singleembodiment, may also be provided separately or in any subcombination.Further, reference to values stated in ranges includes each and everyvalue within that range. Many other embodiments may be apparent toskilled artisans only after reading this specification. Otherembodiments may be used and derived from the disclosure, such that astructural substitution, logical substitution, or another change may bemade without departing from the scope of the disclosure. Accordingly,the disclosure is to be regarded as illustrative rather thanrestrictive.

What is claimed is:
 1. A glass mat comprising: an assembly of glassfibers; and a binder composition comprising an organic resin and anadhesion promoter comprising a resin acid additive, a tall oil fattyacid, a rosin, a tall oil derivative, or combination thereof.
 2. Theglass mat of claim 1, wherein the organic resin comprises aurea-formaldehyde composition.
 3. The glass mat of claim 2, wherein theurea-formaldehyde composition further comprises a styrene maleicanhydride copolymer.
 4. The glass mat of claim 3, wherein theurea-formaldehyde and the styrene-maleic anhydride copolymer are presentin a weight ratio of 99.9:0.1 to about 70:30.
 5. The glass mat of claim1, wherein the adhesion promoter comprises a tall oil fatty acid.
 6. Theglass mat of claim 1, wherein the adhesion promoter is present at anamount of up to about 10.0% by weight, based on the total weight % ofthe binder composition.
 7. The glass mat of claim 6, wherein theadhesion promoter is present at an amount of about 1.0% by weight toabout 5.0% by weight, based on the total weight % of the bindercomposition.
 8. The glass mat of claim 1, wherein the binder compositionfurther comprises an acrylic latex.
 9. The glass mat of claim 8, whereinthe acrylic latex is present at an amount of up to about 15.0% byweight, based on the total weight % of the binder composition.
 10. Theglass mat of claim 1, wherein the binder composition fixedly bonds theassembly of fibers.
 11. The glass mat of claim 1, wherein the bindercomposition is about 3% by weight to about 45% by weight of the glassmat.
 12. The glass mat of claim 11, wherein the binder composition isabout 15% by weight to about 25% by weight of the glass mat.
 13. Theglass mat of claim 1, wherein the assembly of fibers includes anon-woven mat.
 14. The glass mat of claim 13, wherein the non-woven matincludes randomly disposed fibers.
 15. The glass mat of claim 1, whereinthe assembly of fibers includes an A-type glass fiber, a C-type glassfiber, an E-type glass fiber, an S-type glass fiber, an E-CR-type glassfiber, a wool glass fiber, or a combination thereof.
 16. The glass matof claim 1, wherein the assembly of fibers have a length of about 0.75inches to about 3 inches.
 17. The glass mat of claim 1, wherein theassembly of fibers have a diameter of about 3 microns to about 20microns.
 18. The glass mat of claim 1, wherein the glass mat has aweight of about 0.5 pound/100 square feet to about 6.0 pound/100 squarefeet.
 19. The glass mat of claim 18, wherein the glass mat has a weightof about 0.5 pound/100 square feet to about 4.0 pound/100 square feet.20. The glass mat of claim 1, wherein the glass mat further comprises aloss on ignition (LOI) value of not greater than about 30%.